A cap and method of manufacturing a cap

ABSTRACT

A baseball cap ( 100 ) and method of assembling thereof is provided. The cap ( 100 ) includes a single-panel crown ( 110 ) that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown ( 110 ) has a hemispherical shape. The cap ( 100 ) further includes a support layer ( 230 ), such as made from buckram, which is attached to an interior, front portion of the single-panel crown ( 110 ), and a visor ( 120 ) and an elastic band ( 260 ) which are attached to the single-panel crown ( 110 ).

FIELD

The present disclosure is related to a method of assembling ormanufacturing headwear such as a cap, and more particularly, to a capassembly that incorporates a single-panel crown formed of stretchablefabric.

BACKGROUND

Headwear can include various components, such as a crown and a visor(e.g., bill). One type of headwear is a hat, such as a cap or a baseballcap, in which the crown is traditionally formed of six (6) crown panelsor 5/4/3/2 crown panels because the fabric is flat, unless the crown isspecially hand-crocheted with yarn. However, the multiple crown panelsare connected together using conventional attachment techniques, such asstitching or sewing. Such conventional manufacturing techniques increasethe time, complexity and cost of assembling or manufacturing componentsof a cap together. These types of conventional caps also are restrictivein terms of head size ranges, and thus, must be made in many differentsizes to accommodate different wearers. Furthermore, the materials usedfor the flat crown panels in these caps are susceptible to wrinkling,particularly those which use heavier fabrics.

SUMMARY

A cap and method of assembling thereof is provided, which employ asingle-panel crown formed of a stretchable fabric. The method ofassembling a cap, such as for example a baseball cap, involves forming asingle-panel crown for a cap from a single sheet or single piece ofstretchable fabric, attaching a support layer to an interior, frontportion of the single-panel crown with an adhesive, and attaching avisor and an elastic band to the single-panel crown with the attachedsupport layer. The single-panel crown can be formed by heating andstretching the single sheet or single piece of stretchable fabric toform a hemispherical shape on a portion of the stretchable fabric, andcutting any extra edge portion or portions of the stretchable fabricthat extend from or beyond the hemispherical shaped portion in order toform the single-panel crown for the cap. Heat can be applied to one orboth sides of the stretchable fabric, and as heat is applied, a pressingforce can be applied to the stretchable fabric using a hemisphericalshaped fabric mold to stretch the portion of the stretchable fabric intothe hemispherical shape. The stretchable fabric can be made of a wovenor non-woven material, and can be an elastic fabric (or fabric withelastic properties) that includes 2% to 5% spandex, preferably around3%. of spandex.

The support layer can be made of buckram. To attach the support layer tothe single-panel crown, a coat of an adhesive can be applied to asurface of the buckram or an interior, front portion of the single-panelcrown. The buckram can then be pressed (e.g., heat pressed) against theinterior, front portion of the single-panel crown so that the adhesivebonds the buckram to the interior, front portion of the single-panelcrown. Furthermore, bonding tape can be applied over one or more seamsthat are formed between an edge of the buckram and an interior surfaceof the single-panel crown. Each of the one or more seams extendsradially from an interior, central portion to a bottom edge of thesingle-panel crown, and the bonding tape covers the one or more seamsand further connects the buckram to the single-panel crown.

The cap with a single-panel crown is designed to provide numerousbenefits over conventional caps. For example, the single-panel crown canbe formed from a stretchable fabric in a manner that requiressubstantially less labor in comparison to conventional crowns such asthose formed by connecting multiple flat crown panels or by handcrocheting yarn. Thus, with a single-panel crown design as describedherein, it is possible to assemble or manufacture a cap (e.g., abaseball cap) in a more efficient, faster and less costly manner incomparison to conventional caps. Furthermore, a cap with such asingle-panel crown is able to cover a larger range of head sizes, hasincreased or improved tear strength by eliminating the need forstitching ordinarily employed to connect multiple flat crown panelstogether in conventional caps, and is less susceptible to wrinklingparticularly when employing light or lighter stretchable fabric for thecrown.

BRIEF DESCRIPTION OF THE DRAWINGS

The description of the various exemplary embodiments is explained inconjunction with the appended drawings, in which:

FIG. 1 is a perspective view of an example headwear, such as an examplecap that incorporates a single-panel crown formed from a single sheet orsingle piece of stretchable fabric, in accordance with an exemplaryembodiment of the present disclosure.

FIG. 2 is a bottom view showing an interior or inside of thesingle-panel crown of the cap in FIG. 1.

FIGS. 3 through 8 illustrate various operations involved in an exemplaryprocess of assembling or manufacturing a cap such as in FIG. 1.

FIG. 9 is a flow diagram of an exemplary process of assembling ormanufacturing headwear, such as the cap in FIG. 1.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIGS. 1 and 2 illustrate a headwear, such as a cap 100. As shown in FIG.1, the cap 100 includes a single-panel crown 110. A top button 112 and avisor 120 are attached (or connected) to the crown 110. The single-panelcrown 110 has a hemispherical shape (e.g., a dome shape) and is formedof a stretchable fabric, preferably a light or lighter stretchablefabric. The fabric can be a woven or non-woven material, and can be anelastic fabric that is formed, such as for example with spandex (e.g.,between 2% and 5% spandex, preferably around 3% spandex). As will bedescribed in greater detail below, the single-panel crown 110 can beformed by heating and stretching a single sheet or single piece of astretchable fabric into a hemispherical shape using a heat pressingsystem or heat press transfer machine with a suitable fabric-shapingmold or fabric mold (e.g., a hemispherical-shaped fabric mold).

As further shown in FIG. 2, the cap 100 also includes a support layer230, and an elastic band 260. The support layer 230 is attached to aninterior or inside of the single-panel crown 110 to provide structuralsupport for a desired portion(s) of the single-panel crown 110 of thecap 100. In this example, the support layer 230 is attached to aninterior, front portion of the single-panel crown 110.

The support layer 230 can be formed as a single panel or by connectingmultiple support panels. For example, as shown in FIG. 2, the supportlayer 230 includes two support panels 230A and 230B, which can beconnected together along their seam such as, for example, by sewing orstitching, with bonding tape, with an adhesive, or a combinationthereof. In this example, the two support panels 230A and 230B togetherwith a strip 240 of bonding tape or fabric are stitched and the strip240 covers the seam between the support panels 230A and 230B. Thesupport layer 230 can be formed of a rigid material, such as buckram.

The support layer 230 can be attached to the interior or inside of thesingle-panel crown 110 through heat transfer techniques using anadhesive (e.g., a fabric adhesive), as well as using bonding tape. Asshown in FIG. 2, two strips 250A and 250B of bonding tape are appliedalong respective seams between an outer edge or periphery of the supportlayer 230 and the interior of the single-panel crown 110. The strips250A and 250B of bonding tape further attach the support layer 230 tothe single-panel crown 110, and cover respective seams therebetween thatextend radially from a central or center portion to a bottom edge (orrim) 114 of the single-panel crown 110. The bonding tape, as usedherein, can be a single-sided or double-sided heat bonding tape oradhesive tape (e.g., a pressure sensitive adhesive tape). An adhesive,as used herein, can be a fabric adhesive that is applied with or withoutheat to bond two or more components together.

The elastic band 260 is attached around an interior of the bottom edge114 of the single-panel crown 110 with the attached support layer 230.The elastic band 260 can be a sweatband. The visor 120 and the elasticband 260 can be attached to the single-panel crown 110 by sewing orstitching them to the single-panel crown 110 (see e.g., stitches orstitching 116 in FIG. 1).

FIGS. 3 through 8 illustrate an exemplary step-by-step process ofassembling or manufacturing a cap with a single-panel crown, such asshown in FIG. 1. As shown in FIGS. 3 and 4, a single sheet or singlepiece of stretchable fabric 310 is provided. The stretchable fabric 310can be an elastic fabric. A portion of the stretchable fabric 310 isheated and pressed with a sufficient force by a hemispherical-shapedfabric mold 10 (of a heat press transfer machine or heat pressingsystem) to form a hemispherical shape on the fabric 310, i.e., ahemispherical-shaped portion 410. The amount of force, temperature andtime used in the heating and stretching processes can vary according tothe properties of the stretchable fabric 310 in the heating andstretching operations. The size and shape of the mold 10 can be changed,as desired, to accommodate different types of caps and head sizes orhead size ranges.

As shown in FIG. 5, the stretchable fabric 310 is subsequently cut ortrimmed, if necessary, to remove any extra edge portion or portions 510that extend beyond the hemispherical-shaped portion 410. In this way, asingle-panel crown 110 is formed from the hemispherical-shaped portion410 of the stretchable fabric 310. As an alternative, the stretchablefabric 310 can be cut beforehand or pre-cut into a fabric blank (e.g., acircular or oval blank of the stretchable fabric 310) with a suitablesize and shape to avoid the necessity of performing a trimming orcutting operation after the heating and stretching processes. Forexample, the fabric blank can be heated and stretched, as describedherein, to form the single-panel crown 110 with a hemispherical shape.

As shown in FIG. 6, a support layer 230 is to be attached to an interioror inside of the single-panel crown 110, which is noted by reference600. In this example, the support layer 230 is formed of two supportpanels 230A and 230B (e.g. triangular-shaped panels), which areconnected by sewing or stitching along a seam formed by adjacent outeredges of the support panels 230A and 230B. For example, a strip 240 offabric or bonding tape, which is applied over the seam between thesupport panels 230A and 230B, is sewed or stitched to attach or tofurther attach the support panels 230A and 230B along with the strip 240together. However, the support panels 230A and 230B can be attached inother ways, such as using adhesives (e.g. fabric adhesives), bondtaping, etc.

As shown by reference 700 in FIG. 7, the support layer 230 can beattached to the interior or inside of the single-panel crown 110 usingan adhesive 630 (e.g., fabric adhesive). For example, a coating of theadhesive 630 is applied on one side or surface of the support layer 230.The support layer 230 is thereafter inserted into the single-panel crown110, and then pressed against an interior, front portion of thesingle-panel crown 110 to attach the support layer 230 to thesingle-panel crown 110. As shown in FIG. 8, two strips 250A and 250B ofbonding tape are applied along respective seams between an outer edge orperiphery of the support layer 230 and the interior of the single-panelcrown 110 (also referred to as “seamless taping”). The strips 250A and250B of bonding tape further attach the support layer 230 to thesingle-panel crown 110, and cover respective seams therebetween thatextend radially from a central or center portion to a bottom edge (orrim) 114 of the single-panel crown 110. The top button 112 is alsoattached to a central portion or center of the single-panel crown 110with a metal snap or the like.

As further shown in FIG. 8, a visor 120, an elastic band 260 areattached to the single-panel crown 110 with the support layer 230. Forexample, the elastic band 260 is attached around an interior of thebottom edge 114 of the single-panel crown 110 with the attached supportlayer 230. The visor 120 and the elastic band 260 can be attached to thesingle-panel crown 110 by sewing or stitching them together to thesingle-panel crown 110 (see e.g., stitches or stitching 116 in FIG. 1)or separately. to the single-panel crown 110.

FIG. 9 is a flow diagram of an exemplary process 900 by which aheadwear, such as for example a cap as shown in FIG. 1, is assembled andmanufactured with a single-panel crown. The process 900 can begin withthe provision of a single sheet or single piece of stretchable fabric,at reference 902. The stretchable fabric can be made of woven ornon-woven material, and can preferably be a light or lighter stretchablefabric. As previously discussed, the stretchable fabric can be anelastic fabric that incorporates spandex, such as for example between 2%to 5% of spandex or preferably around 3% of spandex.

At reference 904, the stretchable fabric is heated and stretched so atleast a portion thereof forms a hemispherical shape (e.g., a dome orhalf-sphere shape). A hemispherical-shaped fabric mold or other suitablefabric mold of a heat press transfer machine or heat pressing system canbe used to heat press, and thus, stretch the stretchable fabric into adesired shape (or dimensions). The stretchable fabric can be heated onone or both sides when stretching the fabric.

At reference 906, any extra edge portion or portions of the stretchablefabric that extend from or beyond the hemispherical-shaped portion iscut or trimmed off in order to form a single-panel crown for a cap.

At reference 908, a support layer is attached to an inside or interiorsurface of the single-panel crown. For baseball or similar caps, thesupport layer can be attached to an interior, front portion of thesingle-panel crown. As previously discussed, the support layer can bemade of buckram, and can be formed of one or more support panels whichare attached together such as by sewing or stitching, adhesive (e.g.,fabric adhesive), bonding tape or a combination thereof, or by otherconventional attachment techniques. For example, the support layer caninitially be attached to the single-panel crown with an adhesive, andthen bonding tape can be applied over the seams between outer edge orperiphery of the support layer and the interior of the single-panelcrown.

At reference 910, the visor and the elastic band (e.g., a sweatband) isattached to the single-panel crown, such as by sewing or stitching. Thevisor and the elastic band can be attached separately to thesingle-panel crown or attached together (e.g., at the same time orsimultaneously) to the single-panel crown.

At reference 912, other cap manufacturing processes may be performed tocustomize the cap. For example, these and other conventional capmanufacturing processes may include embroidering a logo(s) or printing alogo(s), e.g., a print logo, on the cap.

The headwear and method of assembling thereof, which are shown anddescribed above with reference to the figures, are simply provided asexamples. It should be understood that the headwear can include asingle-panel crown having a different or varying size, shape andconfiguration. Although the headwear in FIGS. 1 and 2 is shown as aparticular type of a cap, such as a baseball cap, the single-panel crownmanufacturing technique can be used to assemble or manufacture othertypes of caps with a visor (e.g., a bill) and having a different orvarying dimensions (e.g., size and shape). In general, headwearcomponents (including those described herein), layers of materials oraccessories (e.g., lining, liners or backing for the single-panel crown,etc.) can also be attached or connected using various attachmenttechniques, such as sewing or stitching, adhesive (e.g., fabricadhesive), bonding tape, or a combination thereof and/or otherconventional techniques for attaching components of a headwear together.Furthermore, the assembling operations can be performed in a differentorder, and may omit some operations or add other operations to assemblea cap with a single-panel crown.

As discussed herein, a stretchable fabric can be heated and stretchedinto a desired shape with a heat press transfer machine or heat pressingsystem that employs fabric mold. The fabric mold can include a male moldpart (e.g., mold 10 in FIGS. 3 and 4) and a counterpart-female moldpart, which when engaged stretches the stretchable fabric arrangedtherebetween into a desired shape according to the shape of the moldparts (e.g., hemispherical shape). Alternatively, the fabric mold mayinclude only a male mold part, upon which the stretchable fabric ispressed against and stretched.

Words of degree, such as “about”, “substantially”, and the like are usedherein in the sense of “at, or nearly at, when given the manufacturing,design, and material tolerances inherent in the stated circumstances”and are used to prevent the unscrupulous infringer from unfairly takingadvantage of the invention disclosure where exact or absolute figuresand operational or structural relationships are stated as an aid tounderstanding the invention.

While particular embodiments and applications of the present disclosurehave been illustrated and described, it is to be understood that thepresent disclosure is not limited to the precise construction andcompositions disclosed herein and that various modifications, changes,and variations can be apparent from the foregoing descriptions withoutdeparting from the invention.

What is claimed is:
 1. A method of assembling a cap comprising: forminga single-panel crown for a cap from a single sheet or single piece ofstretchable fabric; attaching a support layer to an interior portion ofthe single-panel crown; and attaching a visor and an elastic band to thesingle-panel crown with the attached support layer.
 2. The methodaccording to claim 1, wherein the forming a single-panel crowncomprises: heating and stretching the single sheet or single piece ofstretchable fabric to form a hemispherical shape on a portion of thestretchable fabric.
 3. The method according to claim 2, wherein theforming a single-panel crown further comprises: cutting any extra edgeportion or portions of the stretchable fabric that extend from or beyondthe hemispherical shaped portion in order to form the single-panel crownfor the cap.
 4. The method according to claim 2, wherein the heating andstretching comprises: applying heat to one or both sides of thestretchable fabric; and as heat is applied, applying a pressing forcewith a hemispherical shaped fabric mold to stretch the portion of thestretchable fabric into the hemispherical shape.
 5. The method accordingto claim 1, wherein the stretchable fabric comprises a woven ornon-woven material.
 6. The method according to claim 5, wherein thestretchable fabric includes 2% to 5% spandex.
 7. The method according toclaim 1, wherein the support layer comprises buckram, the attaching asupport layer comprising: applying an adhesive to a surface of thebuckram or an interior, front portion of the single-panel crown; andpressing the buckram against the interior, front portion of thesingle-panel crown so that the adhesive bonds the buckram to theinterior, front portion of the single-panel crown.
 8. The methodaccording to claim 7, further comprising: applying bonding tape over oneor more seams that are formed between an edge of the buckram and aninterior surface of the single-panel crown, each of the one or moreseams extending radially from an interior, central portion to a bottomedge of the single-panel crown, the bonding tape covering the one ormore seams and further connecting the buckram to the single-panel crown.9. The method according to claim 1, wherein the attaching a visor and anelastic band comprises stitching the visor and the elastic band to thesingle-panel crown, the elastic band attached around an interior, bottomedge of the single-panel crown.
 10. The method of claim 1, wherein thecap is a baseball cap, and the elastic band is a sweatband.
 11. Themethod of claim 1, wherein the single sheet or single piece ofstretchable fabric comprises a fabric blank of the stretchable fabric,wherein the forming a single-panel crown comprises: heating andstretching the fabric blank of the stretchable fabric to form asingle-panel crown having a hemispherical shape.
 12. Headwear comprisinga cap that includes: a single-panel crown formed from a single sheet orsingle piece of stretchable fabric and having a hemispherical shape; asupport layer attached to an interior portion of the single-panel crown;and a visor and an elastic band that are attached to the single-panelcrown.
 13. The headwear according to claim 12, wherein the stretchablefabric comprises a woven or non-woven material.
 14. The headwearaccording to claim 13, wherein the stretchable fabric includes 2% to 5%spandex.
 15. The headwear according to claim 12, wherein the supportlayer comprises buckram, which is heat bonded to an interior, frontportion of the single-panel crown using an adhesive.
 16. The headwearaccording to claim 15, further comprising: bonding tape applied over oneor more seams that are formed between an edge of the buckram and aninterior surface of the single-panel crown, each of the one or moreseams extending radially from an interior, central portion to a bottomedge of the single-panel crown, the bonding tape covering the one ormore seams and further connecting the buckram to the single-panel crown.17. The headwear according to claim 12, wherein the visor and theelastic band are stitched to the single-panel crown, the elastic bandbeing attached around an interior, bottom edge of the single-panelcrown.
 18. The headwear according to claim 12, wherein the cap is abaseball cap, and the elastic band is a sweatband.